Stapling machines



Sept. 22, 1959- Filed March 10. 1955 H. K. HAZEL ET AL STAPLING MACHINES 7 Sheets-Sheet 2 INVENTORS Herb 1 K. Haze/ d1 561 /7 l/osson Sept. 22, 1959 H. K. HAZEL ETAL 2,904,785

STAPLING ma mas Filed latch 10, 1955 7 Sheets-Sheet s INVENTORS Her'ber'i' K. Haze/ d Ber/1Q l/ossor/ H. K. HAZEL EI'AL 2,904,786

STAPLING MACHINES Sept. 22, 1959 7 Sheets-Sheet 5 Filed March 10, 1955 Sept. 22, 1959 H. K. HAZEL ET AL 2,904,786

STAPLING MACHINES Filed March 10. 1955 7 Sheets-Sheet 7 INVENTORS Herbert A. Haze/ (51 EZP/FCI' Moss-0n United States Patent STAPLING MACHINES Herbert K. Hazel, Kingston, N.Y., and Eernd Vossen, Arlington, Va., assignors to Melpar, Inc., Alexandria, Va., a corporation of New York Application March 10, 1955, Serial No. 493,392

19 Claims. (Cl. 1-2) This invention is an improvement of an invention disclosed in an application for Letters Patent of the United States, Serial No. 413,092, filed March 1, 1954, and entitled, Stapling Machines, which is assigned to the assignee of the present application.

The present invention relates generally to devices for automatically and in succession stapling and soldering electrical components to pre-wired and pre-solder-plated wafers, and more particularly to automatic devices for feeding components from a delivery point to a stapling station, and, thereafter carrying out a series of forming, stapling, and soldering operations designed to secure the component in stapled and soldered relation to a wafer.

Briefly describing the present invention, an elongated chute of generally V-shaped cross section is employed as a conveyor to deliver components from component delivery stations to a stapling station. The components are generally of the type utilized in fabrication of electronic circuits, and comprise a body, which may be cylindrical, and two co-linear leads extending in opposite directions from the body. The chute conveyor contains a number of air passageways terminating along its vertex, distributed along the chute at short intervals, and supplied with air under pressure. The passageways make an angle of about 20-30 with the longitudinal dimension of the chute, and are so arranged that air under pressure emerging from the passageways blows the components along the chute in a desired direction. The specific angle which the air passageways with the chute is selected in accordance with the weight and size of the components to be conveyed and the frictional forces to be overcome.

At the delivery end of the chute is located a stapling station. Each component, as it reaches the stapling station, is cammed in response to its own inertia onto a pair of separable forming blocks, the leads of the component extending in the direction of the line of separation between the blocks, and the component being supported by its leads alone, and the component body hanging free. The blocks are separable in a direction transversely of the line of separation, to permit the component to pass between the blocks during a stapling operation. The blocks are maintained together by solenoid controlled pneumatic motors, and may be separated by these motors in response to energization of a further solenoid.

While the component rests on the forming blocks it serves to reduce light intensity falling on a photo-electric cell. The subsequent reduction of current flow in the circuit of the photo-electric cell serves to fire a thyratron, which in turn energizes a relay and initiates a cycle of operations of the system.

The first operation in the cycle is the de-energization of a solenoid controlling a pneumatic motor which main tains a component insertion head in withdrawn position, and the energization of a further solenoid controls the motor to actuate the insertion head to staple forming position. The insertion head moves down over the form ing blocks to form the component leads as staples, holds steady the component leads, and without touching the relatively fragile component body bends the lead ends over the blocks. As the insertion head completes the staple forming operation, its forming fingers grip the bent leads;

When the insertion head has reached a position corresponding with completion of the forming operation, it actuates a switch, which energizes electro-pneumatic de; vices which separate the forming blocks. When these have separated, the forming head continues its motion, carrying the component past the forming position to a prepared wafer, for insertion therein.

The wafer is pre-positioned on a supporting platform and contains a pair of apertures adapted and positioned to receive the staple-like component. On its under side the wafer includes printed circuitry on which has been plated a heavy layer of solder. The insertion head inserts the formed leads of the component through the apertures, and thereafter retains its position, pressing the com ponent leads firmly.

Completion of separation of the forming heads serves to actuate a switch which prepares, but does not complete, a circuit for a solenoid which controls a pneumatic motor for actuating a stapling and soldering anvil located on the under side of the wafer. It is the function of the stapling and soldering anvil to bend over the lead ends protruding through the wafer apertures, and to heat these ends and the soldered circuitry in proximity thereto sufficiently to effect a soldering operation.

When the insertion head has completed its travel to the wafer, it closes a switch which further partially closes the circuit to an anvil control solenoid. In addition, pneumatic pressure is built up in the insertion head actuating cylinder. This pressure, when it has attained a sufficiently high value, actuates a pressure responsive switch which completes the circuit for'the latter. The anvil now moves up to operating position. But it does so only after the insertion head has reached its final position, and the pneumatic motor which actuates the insertion head has attained sufficient pneumatic pressure to maintain its position against the pressure which will be exerted by the anvil during the stapling and soldering operation.

When the anvil has arrived at operating position, it is held there in response to energization of its holding circuit. It has, at that time, completed the stapling operation, but requires additional time to complete the soldering operation. This required time is supplied in terms of succeeding steps in the cycle of operation of the system.

When the anvil reaches the top of its stroke, its motor actuates a pressure responsive switch which energizes the solenoid controlling the Up cylinder for the insertion head. When the latter has moved up, it actuates a switch which serves to energize the pneumatic motor which serves to bring the forming blocks together, and when these are.

It is, accordingly, a primary object of the present invention to provide an automatic machine for conveying components to a stapling and soldering station, forming the leads of the components as staples, inserting the staples into a prepared wafer, completing the stapling, and soldering the leads to printed circuitry on the wafer.

It is another object of the present invention to provide a staple forming device capable of bending the leads of a relatively fragile electrical component without dam age to the component.

,A further object of the present invention resides 1n the Provision of a staple forming device which includes separable forming blocks, and a staple inserting head which forms-the staples on the blocks, and thereafter carries the formed staples beyond the forming blocks when the blocks are separated.

It is another object of the invention to provide a pneumatically actuated component inserter, wherein the pneumatic elements are electrically controlled.

It is a further object of the invention to provide a pneumatically actuated machine, including a plurality of elec trically controlled pneumatic motors, in which the motors are each actuated by closure of an electrical circuit in response to completion of the operation of another of the motors.

Another object of the invention resides in the provision of a pneumatically operated system in which a plurality of pneumatic motors are electrically controlled, certain of said motors being controlled jointly in accordance with the position and the pneumatic pressure exerted by others of the motors.

Another object of the invention resides in the provision of a system for inserting electrical components in a wafer, and for stapling these components to the wafer by its own leads, the system being wholly automatic and capable of handling a variety of shapes and sizes of components.

The above and still further features, objects, and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment of the invention, especially when taken in conjunction with the accompanying drawings, wherein:

Figure 1 is a View in front elevation of a machine representing a specific embodiment of the present invention;

Figure 2 is a view in side elevation corresponding with Figure 1, taken on the line 22 of Figure 1;

Figure 3 is a view in cross section taken on the line 3-3 of Figure 1;

Figures 4, 5, 6, 10, and 11 are views in transverse cross section, taken on the lines 44, 55, 66, 10, 11-11, respectively, of Figure 3.

Figure 7 is an enlarged view in front elevation showing a component delivery chute and its relation to staple forming and inserting components;

Figure 8 is a view in cross section taken on the line 88 of Figure 7;

Figure 9 is a view in transverse cross section taken on the line 9-9 of Figure 8;

Figure 12 is a view in plan of forming blocks and forming block actuators;

Figure 13 is a view in cross section taken on the line 13-13 of Figure 12;

Figure 14 is a view in cross section of a staple forming and inserting head;

Figure 15 is a view in cross section taken on the line 1515 of Figure 14;

Figure 16 is a view in cross section taken on the line 1616 of Figure 14;

' Figures 17-21, inclusive, are views in front elevation showing the relationships of elements of the staple forming and inserting head during operation of the latter; and

Figure 22 is a schematic diagram of the control circuits for the various electrically controlled elements of the invention.

Figure 23 is a view in plan of a wafer, with component assembled thereto, in accordance with the invention; and

Figure 24 is a view in transverse section of the wafer of Figure 23.

Circuitry Referring now to the accompanying drawings, and more specifically to Figure 22 thereof, a source of 115 v.

' A.C. supply, 1, energizes a voltage step-down transformer T via manual switch S. The secondary winding of transformer T in turn energizes a voltage step-up transformer T Connected directly across the primary winding of transformer T is a pair of leads 10, 11. The lead 10 is a common lead for a plurality of solenoids and relays K K inclusive. The lead 11 is connected directly to solenoids K and K via lead 12, maintaining these solenoids energized so long as switch S is closed and power is supplied to the system. Solenoids K and K when energized, open the master air supply lines for certain pneumatic cylinders, hereinafter described.

The lead 11 is also connected to the arm 14 of a relay K having stationary contacts 15 and 16. The contact 15 is connected to a lead 17, while the contact 16 is connected with a lead 18. In the de-energized condition of relay K arm 14 makes to contact 15, and completes a circuit via lead 17 for solenoid K which serves to hold insertion head 19 in Up position, preparatory to initiation of a component insertion operation.

A relay K is connected across the secondary winding of transformer T in series with resistance 21. An exciter lamp 20 is connected in parallel with the relay, and being of low resistance maintains the relay de-energized while the lamp 20 is operative. When lamp 2t} burns out, the shunt is removed, and an energizing circuit is available for relay K across the secondary windings of transformer T via resistance 21. Relay K is then energized. The movable arm of relay K then pulls up to blank contact 23. In the de-energized condition of relay K arm 22 completes a circuit to contact 24, which is connected in series via current-limiting resistance 25, relay K and the anode 27 of a thyratron 28. The arm 22 is also connected with a lead 29' connected to one terminal of the secondary winding of transformer T In consequence, the relay 26 and the thyratron 28 are supplied with alternating voltage so long as eXciter lamp 20 remains operative, and are deprived of voltage when exciter lamp 2t) burns out.

The lead 29 is further connected to bleeder resistances 3t), 31, in series, and thence directly to the cathode 32 of thyratron 28, which is in turn connected via resistance 33 to lead 34, connected to the other terminal of the secondary winding of transformer T The potential of cathode 32 is thus established at a value negative with respect to the voltage of anode 27, when the latter is positive. The grid 35 of thyratron 28 is supplied with voltage from a variable tap 36 on resistance 31, in series with a voltage-dropping resistance 37. The grid 35 is connected directly with the anode 49 of photo-electric cell 41, the cathode 42 of which is connected to lead 34. When anode 27 is positive, so also is anode 4% so that current flows through photo-cell 41, and via resistance 37, in such direction as to apply negative going hold-off voltage to grid 35 of thyratron 28. The thyratron is thus prevented from firing so long as photo-cell 41 is illuminated. When photo-cell 41 is no longer illuminated the negative going hold-off voltage across resistance 37 is no longer available. The thyratron 23 then fires whenever its anode voltage goes positive.

While the thyratron 28 is firing, relay 26 is energized, anl lead 11 is then connected via contact 16 to lead 18, solenoid K being then de-energized and solenoid K energized.

The interruption of illumination of photo-cell 41 is caused by positioning of a component 42 on forming blocks 45, 46, between lamp 20 and photo-cell 41. A

wafer 43 is positioned under the component 42, and con tains a pair of apertures for reception of the leads of the component 42.

The component 42, when supplied to the forming blocks, 45, 46, has leads extending axially in opposite directions. The leads are the only parts of component 42 which are supported by forming blocks 45, 46, the body of the component hanging free. The forming blocks 45, 46 are normally pressed together by pneumatic devices, so long as solenoid K is energized. The solenoid K is energized, via switch S and lead 17, so long as thyratron 28 remains unfired.

When thyratron 28 fires, relay K pulls up, energizing lead 18. Lead 18 supplies a circuit for insertion head control solenoid K via switch S The insertion head 19 now moves down, in consequence of the de-energization of solenoid K and the energization of solenoid K forming the leads of component 42, by bending these at right angles to the body of the component over the forming blocks 45, 46.

When the insertion head 19 reaches the bottom of its forming stroke it actuates switch S which opens the circuit of solenoid K and closes the circuit to solenoid K De-energization of solenoid K removes pressure from the pneumatic devices which hold the forming blocks 45, 46 together, and ener-gization of solenoid K supplies pneumatic pressure to the pneumatic devices which pull the forming blocks 45, 46 apart.

t The forming blocks 45, 46 now separate, permitting the insertion head to carry the component 42 down past the forming block position, and to insert its leads through the apertures in the wafer 43.

In the operations described immediately hereinabove, a circuit was maintained from lead 12 via switch S to solenoid K which energizes a pneumatic switch for maintaining anvil 47 in retracted position.

When the forming blocks 45, 46 separate they actuate the switch S to break the circuit to solenoid K and to prepare a circuit for relay K and solenoid K The latter circuit, however, remains incomplete so long as either of switches S7 and S connected in series, remain open. Switch S is closed in response to the insertion head, 19, when the latter reaches its lowermost position, signaling that a component 42 has been inserted in wafer 43. Switch 8,; is a pneumatic switch which operates on attainment of predetermined pressure in the pneumatic actuating cylinder for the insertion head 19 during the down stroke only. This pressure is selected to be adequate to withstand the pressure which will be applied by the anvil 47, in completing a stapling and soldering operation. When switches S7 and S are both closed, a circuit is completed for both relay K and solenoid K Solenoid K serves to energize the pneumatic cylinder which actuates anvil 47 into stapling and soldering position. Relay K is a holding relay, which actuates switch arm S to complete a shunt-holding circuit for relay K and solenoid K around switches S7 and S This circuit is then maintained so long as switch S remains actuated by forming blocks 45, 46 in their separated condition.

The anvil 47 now moves up and completes the stapling and soldering operation. In so doing it develops pressure in its pneumatic system, eventually suflicient to actuate switch S Operation of switch S breaks the circuit to solenoid K and re-makes the circuit to solenoid K which energizes a pneumatic motor for raising the insertion head 19. When the latter has completed its rise it actuates switch S to normal position (as illustrated). Solenoid K is thereby de-energized, and solenoid K energized, and the forming blocks 45, 46 moved in, to forming position. The latter operation actuates switch S to normal position (as illustrated), de-energizing relay K and solenoid K and energizing solenoid K The anvil 47 then withdraws, and the cycle of operations is completed.

6 Structure Referring now more particularly to Figures 1-21 of the accompanying drawings, a staple forming and inserting head 19 is supported on one or more cross beams 50, and includes a pneumatic actuating motor generally identified by the reference numeral M Similarly, the stapling and soldering anvil 47 is supported by one or more cross beams 52, and is actuated by a pneumatic motor M Intermediate the staple forming and inserting head 19, and the stapling and soldering anvil 47 is located a wafer holder 54, supported from the cross-beams 52 by means of pillars 55, and having provision for supporting rigidly a thin, apertured wafer 43. it is the function of the machine described to form the leads of electrical components, such as electrical resistors or condensers or the like, having two leads extending in opposite directions and collinearly, to insert the formed leads in the apertures in the wafer 43, to bend over the lead ends which extend through the apertures, and to solder the bent-over leads to pre-solder plated printed circuitry secured to the under-side of the wafer. To this end a component 42 is supplied to a conveyor 50 (Figures 7, 8, and 9) from any one of a plurality of component supply devices. For the purpose of the present disclosure, the component 42 may be assumed to be placed on the conveyor 50, at any point thereof, by hand. In a practical machine, however, an automatic machine may be employed for this purpose, for example, a machine such as is described in an application for Letters Patent of the United States, filed December 6, 1954, in the name of Bernd Vossen, Serial No. 473,251, and assigned to the assignee of the present application. in the latter application the channel 37 may correspond to the conveyor 50 in the present application.

The conveyor is in the form of a V-shaped channel 50, and consists of two separate elongated elements C C; which feed components in opposite directions, respectively, to a common forming and stapling station 55. Describing one of the conveyors, C as typical, the V-shaped channel includes sloping sides making an angle of approximately one to the other, the specific angle being unimportant, and selected primarily for convenience. The junction of the sloping sides is not sharp, but is truncated slightly, to form a flat at 56. Located under the channel 56 is a further channel 57, which communicates with an inlet fitting 58, in turn coupled to suitable pneumatic piping, 59, which supplies air under pressure to the channel 57 from a suitable source of compressed air. The channel 57 communicates with the V-channel 50 via a large number of spaced openings 60, which extend into the base of the V-channel 50 at a relatively small angle, say 20, for example, sloping upwardly toward the forming and stapling station 53, and which are relatively elongated and of small cross section, so that directional jets of air are supplied to the base, 56, of the channel.

The net efiect of the air emerging from the openings 54, is to tend to lift the component 42, and thus to reduce frictional forces, and simultaneously to apply force to component 42 tending to slide the latter toward the station 53. The apertures 60 are distributed along the entire length of the conveyor 51, and are suificiently closely spaced in relation to the length of the conveyed component 42, that the component 42 is subject to sliding force in response to an air jet from at least one of the apertures 64), regardless of its momentary position along the conveyor 51.

The angle which the openings 54 make with the base 56 of the conveyor channel 50 has been found to have an optimum, which is not unduly critical, and which depends on the size of the apertures 60, on the size and weight and configuration of the component 42, and on the air pressure utilized, and on the number of openings per inch of conveyor. This optimum angle, for which motion of the component 42 is rapid, smooth, and linear, is determined empirically, and has been found to be about 20 in one practical embodiment of the present device.

When the component 42 has arrived at the delivery end of the conveyor 51, the component is impelled by its inertia to cross the space between the conveyors C C between which lie the forming blocks 45, 46. As the forward end 61 of the component leaves its conveyor, said C it begins to drop, while the rearward end remains supported. However, the motion of the component 42 along the chute is sufficiently rapid that the end 61 of the forward lead reaches a camming surface 62. Continued forward motion of the component results then in camming upward of the forward end 61 of the component 42. The camming surface 62 is so designed, in relation to the level of the forming blocks 45, 46, as to permit the forward end of the component to pass over the forming blocks, 45, 46, and the rearward end to be deposited thereon as soon as the component has left the conveyor. The forward end of the component then also drops, and the component lies accurately positioned on the forming blocks 45, 46, ready for a forming operation. It is requisite to this end that the forming blocks 45, 46 be V-shaped, so that the component may lie accurately in the V, and hence may be accurately positioned laterally, for subsequent operations. At the same time it is essential that the position of the component longitudinally be maintained, and that this maintenance be independent of the length of the component body. To this end, the leads of the component are accurately cut, in advance of feeding to the machine, so that each lead extends the same distance from the body of the component as does the other lead, i.e. so that leads and body are symmetrical, and so that the total length of the component, taken from lead end to lead end, has a predetermined value. The latter length is just short, by a few thousandths of an inch, of the distance between the adjacent ends of the con veyors C C The component 42, in dropping between the adjacent ends of conveyors C C then comes into position longitudinally.

Considering now the forming blocks 45, 46, per se, each includes a block of metal, of generally L-shaped configuration, the bases 65, 66 of the Us extending toward one another, and the vertically extending arms 67, 68 having vertical slots 69, 70 formed therein, and horizontally extending apertures 71, 72 communicating with the slots 69, 70. Extending into the slots 69, 70, via the apertures 71, 72, is a pair of actuating rods 73, 74, which are secured to the arms 67, 68, as by locking rings 75, 76. Accordingly, the forming blocks 45, 46 may be separated or conjoined by motion applied to the rods 73, 74.

Slots 77, 78 are formed in the blocks 45, 46, which extend parallel with the rods 73, 74, and in which are inserted resinous blocks 79, 80. The resinous block 79 contains the photo-electric cell 41, and the resinous block 80, the light source 20, which are energized, respectively, from terminals 83, 84, supported in the resinous blocks 79, 80. The light source 20, and the light input end of the photocell 41, face each other, via apertures 81, 82 in the resinous blocks 79, 80, so that in the absence of a component 42 on the forming blocks 45, 46 the photo-cell 41 is illuminated. When a component 42 arrives at its eventual position on the forming blocks 45, 46 the component blocks the light, so that the photo-cell 41 becomes nil-illuminated, or has its illumination reduced.

The forming elements of the forming blocks 45, 46 consists of U-shaped elements 85, 86. The U-shaped element 85 includes arms 87, 88, the arm 88 being slightly the longer. The U-shaped element 86 includes arms 09, 90, the arm 89 being slightly the longer. The arms 87, 89 extend toward each other and slope each at an angle of about 45 to the horizontal, to provide a V, when taken conjointly. The arms 88, 90, extend parallel to the arms 87,89 and slope similarly. The longer arm- 88, and the longer arm 89, each terminates in a horizontal flat, the flats being respectively identified by the reference numerals 91, 92, and lie in the same line taken transversely of the forming blocks 45, 46. It is on the flats 91, 92 that the leads of a component 42 rest, during a forming operation, and the body of the component is suspended freely between the arms.

It will be recalled that in the description of the circuitry of the present invention, it was recited that interruption of lights impinging on the photo-cell 41 initiates a cycle of operations of the system. While the photo-cell is ex cited the thyratron K remains unfired, and consequently switch arm 14 rests on contact 15. In this condition of the circuitry solenoids K K and K are energized, which serves to maintain'the insertion head 19 Up, the forming blocks 45, 46 In and the anvil 47 Down. For purposes of simplification the various solenoid operated pneumatic valves are illustrated functionally in Figure 2 of the accompanying drawings, and are identified by the same reference symbols as are the solenoids of Figure 22 of the accompanying drawings.

It will be clear, by reference to Figure 2 of the accompanying drawings, that energization of solenoid K supplies air under pressure to line 93 and hence to the under-side of the piston of pneumatic motor M that energization of relay K opens the pneumatic valve which supplies air under pressure to line 95 and hence to the outward sides of the pistons of the pneumatic motors M M which then exert force against rods 73, 74, to hold the forming blocks 45, 46 together; and that energization of solenoid valve K serves to supply air under pressure via line 97, to the upper side of the piston included in pneumatic motor M When the thyratron fires the relay K is tie-energized throwing the arm 14 to contact 16, energizing solenoid K and thereby applying air under pressure to the upper wall of the piston of pneumatic motor M Simultaneously, solenoid K is deenergized removing pneumatic pressure from the under-side of the piston.

Referring now to Figure 3 of the accompanying drawings, when air is supplied to the upper wall of piston of pneumatic motor M the piston 100 proceeds downwardly. The piston 100 is provided with piston rods 101, 102, the former extending upwardly from piston 100, and the latter downwardly, and moves within a stationary cylinder 103. The piston rods 101, 102, and the piston 100 are provided with a continuous axial passage 104, terminating at the lower end of piston rod 102 in a short cylinder 105. Within the cylinder is located a small piston 106, free at its upper end, and having a rod 107 extending from its under-side. The rod 107 extends in air-tight relation through a collar 102a which caps the lower end of the cylinder 103, and at its lower termination is provided with a staple forming head 108. The latter includes a pair of downwardly-extending separated fingers 109 which serve to bend the leads of a component 42 over the flats 9'1, 92 of the forming blocks 45, 46, so that the leads extend at right angles to the body of the component 42.

The portion of the cylinder 103 which is above the piston 100 communicates with the passageway 104 via an aperture 110. Accordingly, when air is admitted above the piston 100, air is also admitted to the passageway 104, and hence to the piston 106. The piston rod 107 extends exteriorly of the head 108, and terminates in a stapleholding head 111. The latter includes laterally separated downwardly-extending lead-holding fingers 112, which subsist between the fingers 109. The spacing of the fingers 112 is equal to that of the flats 91, 92.

On admission of air to cylinder 103 above the piston 100 the staple-forming fingers 109 descend. The stapleholding fingers 112 descend with the fingers 109, and also descend with respect to the fingers 109, in response to pressure on piston 106. The staple-holding fingers 112 reach the leads of-the component 42 before the stapleforming fingers do so, and clamp the component leads against the flats 91, 92. Thereafter, the fingers 112 discontinue their motion, while fingers 109 continue their motion and form the staple.

A relief valve 113 for the passageway 104 is located in a cap 114 at the upper end of the piston rod 101. The relief valve 113 includes an aperture which is normally maintained closed by a ball 115, and by a compression spring 116 which maintains outward pressure on the ball 115.

An actuating rod 117 extends vertically from the cap 118 of the cylinder 103. The length and position of the actuating rod 117 are such, in relation to the position of the ball 114, that when the piston 10% has completed its forming stroke the ball 115 is cammed inwardly of the valve 114, releasing the air in passageway 104 sufiiciently to remove pressure from the piston 106, and thus from the leads of component 42. In this way the separation of forming blocks 45, 46 is facilitated, and possible damage to the component 42 averted, following a staple-forming operation.

The cap 114 is provided with rearwardly-extending fingers 120, which straddle a vertical rod 121 during downward motion of the piston rod 101, to prevent angular motion of the latter at all times. The cap 114 is secured rigidly to the piston rod 101 by means of a transverse pin 122 extending through both.

When the staple-forming fingers 109, and the insertion head 19, have reached a position corresponding with completion of a staple-forming operation, the latter actuates switch S to open the circuit to solenoid K actuates the pneumatic motors 95, 96 to hold the forming blocks 45, 46 together, and to close the circuit to solenoid K which actuates the pneumatic motors 95, 96 to separate the forming blocks 45, 46. The latter then separate. The component 42, the leads of which have been formed as a staple by fingers 109, is retained by the latter due to the resilience of the component leads. The piston rod 102 and the fingers 109 continue their downward travel between the now separated forming blocks 45, 46, to the wafer 43, and passes the downwardly-extending lead ends of the component 42 through apertures provided for the purpose in the wafer 43.

The wafer 43 is fabricated of plastic, and contains apertures for component leads. Since the wafer is relatively fragile it is supported in a recessed steel plate 125, having a recess 126 adapted to receive the wafer 43 snugly, while the plate 125 supports the entire wafer except at points adjacent the operative apertures, where space is provided to permit access to the under side of the wafer 43 by a stapling and soldering anvil 127. The latter is actuated by the stapling and soldering head 47 upwardly into contact with the under-side of the wafer 43, at a suitable point in the cycle of operations of the machine.

The plate 125 is inserted under a pair of lips 128, and I lies on a platform 129, which rests in the four pillars 55. When the forming blocks 45, 46 separate, the forming block 45 opens switch S to break the circuit to the solenoid K which controls the pneumatic motor 53 to hold down the stapling and soldering head 47. The switch S also prepares a circuit for relay K and solenoid K the latter being the solenoid which controls the motor 53 to actuate the head 47 upwardly.

When the staple insertion head 19 reaches the bottom of its stroke, and has completed insertion of the leads of component 42 in wafer 43, the cap 114 closes switch S preparing further the energizing circuit for solenoid K At this point in the cycle of operations the ball 115 attains to the dwell 131 in camming rod 117, and the ball 115, which up to this point had been pressed inwardly by the rod 117 to bleed the passageway 104, again closes leads of component 42 firmly, preparatory to the stapling and soldering operation.

Included in the air line controlled by solenoid K is a pressure responsive switch S Because the component prevents motion of piston 106, following insertion of the leads of component 42 into wafer 43, pressure above piston increases rapidly. This pressure attains in a few moments a value adequate to actuate switch S and this value of pressure is adequate to withstand the pressure of the stapling and soldering anvil 127 in the last stage of the cycle of operation of the machine.

When switch S is actuated, a circuit is completed for hold relay K and for solenoid K Relay K actuates switch S which completes a holding circuit from line 12, through switch S and by-passing switches S and S The hold relay K maintains the last position of switch S and thereby maintains solenoid K in energized condition.

Energization of solenoid K causes pneumatic motor M to actuate anvil 47 Up, into staple forming and soldering position. After the anvil has moved up to stapling position, its further motion is prevented by the wafer 43. Pressure in the pneumatic motor M builds up, and eventtually actuates switch S to de-energize solenoid K and to energize solenoid K The forming head 19 now moves Up. When the upward motion of forming head 19 is complete, switch S is actuated to de-energize solenoid K and to energize solenoid K Forming blocks 45, 46 now move in, and on completion of their motion actuate switch S to de-energize solenoid K and hold relay K and to energize solenoid K The anvil then moves down, and the cycle of operations is complete.

The action of the forming head, holding head and anvil will become evident upon consideration of Figures 14-21 of the accompanying drawings. At the initiation of a cycle of operations the holding head 111 is withdrawn (Figure 14). As the forming head 19 moves down the holding head 111 advances with respect thereto (Figure 17). Just prior to the time the forming fingers 109 commence bending of the leads of component 42 the holding fingers 112 press the leads against the flats 91, 92 of forming blocks 45, 46. The operating surfaces of the forming fingers 109 and the holding fingers 112 are slightly rounded, to accept the cylindrical lead, and to hold same firmly, at points adjacent to the body of the component 42, and on either side thereof. The lead ends protude beyond the forming blocks on either side.

When the holding head 111 has clamped the component leads its motion is interrupted. The forming fingers 109, however, continue downward (Figure 19), and bend the lead ends over the forming blocks 45, 46 so that they extend at right angles to their original directions. The forming blocks are now withdrawn, and the forming fingers 109, now gripping the formed lead ends, carry the component 42 down, and insert the formed lead ends through apertures 43:: in wafer 43 (Figure 20). The anvil 47 now moves up, and bends the protruding lead ends inwardly to complete the stapling operation (Figure 21). which supply heating element 133. A layer of solder 43b is plated to a thickness of about 10 mils over printed circuitry provided on the under-side of water 43, and which passes adjacent to apertures 43a. The heated anvil 127 thus solders the lead ends to the printed circuitry.

The wafer 43 may now be repositioned, and a further component automatically inserted and soldered. The process may be repeated until a complete wired subassembly has been fabricated.

While we have described and illustrated a preferred embodiment of our invention, as required by the pertinent statutes, we desire it to be understood that varia tions of arrangement and structural detail may be re sorted to without departing from the true spirit and scope of the invention as defined by the appended claims. In particular, we realize that where we have employed pneumatic motors, hydraulic motors may be substituted,

The anvil 127 is heated electrically via leads 132,

or electrical motors, or solenoids, or the like, with 'suitable modifications of the arrangement.

What we claim is:

1. In a machine for stapling a component to a wafer, said component having axial leads extending in opposite directions, said wafer having apertures for receiving said leads in stapled relation via one side of said water, the combination of a component insertion head separable lead forming blocks, a wafer holder, first pneumatic means for raising said component insertion head, second pneumatic means for lowering said component insertion head, third pneumatic means for holding said separable lead forming blocks together, fourth pneumatic means for separating said lead forming blocks, and means for actuating said first, second, third, and fourth pneumatic means in predetermined sequence.

' 2. In a machine for stapling a component to a wafer, said component having axial leads extending in opposite directions, said wafer having apertures for receiving said leads in stapled relation, the combination of a stapling head located at one side of said wafer, a pair of separable lead forming blocks located intermediate said water and said stapling head, means for actuating said stapling head for forming said leads against said separable forming blocks, said stapling head including means for holding said formed leads in said stapling head following said forming of said leads, by virtue of the resilience of said leads, means for separating said separable forming blocks following forming of said leads, means for actuating said stapling head for inserting said leads into and through said apertures, wherein each of said means for separating and actuating is a pneumatic device.

3. In a machine for stapling a component to a wafer, said component having axially extending leads, said wafer having apertures for receiving said leads in stapled relation, the combination of a pair of separable forming blocks initially supporting said component, a component insertion head movable from a retracted position through the position of said blocks to said wafer, first means energizable for actuating said insertion head against said leads and said forming blocks so as to form said leads for insertion in said wafer, second means for separating said forming blocks, third means energizable for actuating said insertion head to insert the formed leads through said water and means for actuating said means in predetermined sequence, and arranged so that operation of each means is responsive to a predetermined stage of completion of an operation by a previously actuated means.

4. In a machine for stapling and soldering a relatively fragile component to a wafer, said component initially having leads extending axially in opposite directions, said wafer having solder secured to one side thereof, the combination of means for retaining and supporting said wafer immovably, a pair of forming blocks actuable selectively to forming relation and to separated relation, an insertion head selectively translatable to positions (a) in withdrawn position above said wafer and forming blocks, and (b) in actuated position below said forming blocks and in proximity to said wafer, first means for retaining said forming blocks in forming relation, and said insertion head in withdrawn position, second means for actuating said insertion head into forming relation to said forming blocks, means for separating said forming blocks to permit said insertion head to continue to said wafer, means for thereafter actuating said insertion head to withdrawn position and said forming blocks to forming relation.

5. In a device for forming a staple from a component having a relatively fragile body and a pair of short wires extending in opposite directions from said body, a pair of separable staple forming blocks having a junction, means for advancing said component to said staple forming blocks, means for positioning said component on said staple forming blocks adjacent the junction thereof,

means for sensing the presence of said component in position on said staple forming blocks, means responsive to said sensing means for actuating a staple forming and insertion head in a stroke toward said staple forming blocks, said staple formig and insertion head including means for initially holding portions of said wires located adjacent said body firmly against said forming blocks, means for only thereafter bending the ends of said wires over said forming blocks.

6. The combination in accordance with claim 5 wherein is further provided means responsive to completion of a staple forming portion of said stroke for separating said staple forming blocks sutficiently to allow passage of said staple forming and insertion head in a continuation of said stroke.

7. In a machine for forming a staple from a component having a relatively fragile body and two wires extending in opposite directions therefrom, for inserting said staple into a flat member, and for clinching said staple to said flat member, a pair of separable staple forming elements having a line of junction, means for feeding a component to and positioning said component on said staple forming elements adjacent the line of junction thereof, means for sensing the presence of said component on said staple forming elements, a staple forming and insertion head having a stroke, means responsive to said sensing means for actuating said staple forming and insertion head in said stroke toward said staple forming blocks, said staple forming and insertion head including means for initially holding portions of said wires located adjacent said body firmly against said staple forming elements and finger means for only thereafter bending the unheld ends of said wires over said staple forming elements to form a staple, means operative on completion of staple forming for releasing said means for holding and for separating said staple forming elements to permit further motion of said staple forming and insertion head, said staple remaining held frictionally by said means for bending, and means for positioning said fiat member in the path of said staple.

8. The combination in accordance with claim 7 where in is provided means responsive to attainment of a predetermined force against said staple by said clinching head for initiating a return stroke of said staple forming and insertion head.

9. The combination in accordance wtih claim 8 wherein is further provided means for actuating said staple forming elements toward one another in response 'to the return stroke of said staple forming and insertion head, and means for initiating a return motion of said clinching head in response to predetermined motion of said staple forming elements toward one another.

10. A machine for forming an electrical component as a staple, said component comprising a fragile body and two wire leads extending in Opposite directions and coaxially from said fragile body, said fragile body being larger in cross-section than said wire leads, comprising a first reciprocating unit having an internal cylinder, a piston reciprocable in said cylinder, said first reciprocating unit terminating in a pair of laterally separated staple forming fingers, a rod secured to said piston, said rod terminating in a pair of laterally separated lead pressing fingers, said lead pressing fingers subsisting in the plane of said staple forming fingers and between said staple forming fingers, the distance between said staple forming fingers being less than the distance between the ends of said leads.

11. The combination according to claim 10, wherein is provided a pair of staple forming separable blocks having a line of separation, means for delivering one of said components to said blocks in substantially overlying re lation to said line of separation, said blocks including separated support elements for supporting only said leads of said component at points of said leads adjacent to but 13 slightly separated from said body and substantially separated from the ends of said leads, the width of said blocks adjacent said line of separation being equal to the distance between said staple forming fingers, and the distance between said lead pressing fingers being equal to the distance between said support elements.

12. The combination according to claim 11, wherein is provided means for in turn pressing said leads against said support points by means of said pressing fingers and bending the ends of said leads over said forming block by means of said staple forming fingers while maintaining the pressure of said pressing fingers against said leads and support points.

13. The combination according to claim 12, wherein is provided means for supporting a circuit board under said stapling head and under said forming blocks, and means for separating said forming blocks following said bending of the ends of said leads.

14. The combination according to claim 13, wherein is provided means for actuating said forming fingers and said component with ends bent beyond the separated forming blocks to a position above said circuit board, and means actuating said pressing fingers to move said bent ends through said circuit board.

15. A machine for forming an electrical component as a staple, wherein said component has a fragile relatively thick body and a pair of relatively thin wire leads extending in opposite directions from said body, said machine including separable staple forming blocks, means normally securing said separable staple forming elements in conjoint relation, said forming blocks including two support points and a recess located between said support points, said support points being separated by a distance smaller than the distance between the ends of said leads and greater than the length of said body, said recess being arranged and adapted to receive said body without contact with said body when said leads are supported by said support points.

16. The combination according to claim 15, wherein is provided a photo-cell system for sensing the presence of said component on said forming block and for generating a signal in response to such sensing, a staple forming device located adjacent said staple forming blocks and arranged and adapted to bend ends of said leads over said forming blocks while pressing said leads against said support points to relieve stress on said fragile body, and means responsive to said signal for actuating said staple forming device.

17. The combination according to claim 16, wherein is provided means responsive to completion of bending of said leads over said forming blocks for separating said forming blocks, and means for delivering said component from said staple forming device.

18. In a machine for stapling an electrical component to a wafer, said component having an axially extensive fragile relatively thick body and a pair of oppositely extending relatively thin wire leads, a wafer holder, a staple forming and insertion device located on one side of said wafer and movable in a line generally perpendicular to the plane of said wafer, a pair of separable staple forming blocks located intermediate said wafer holder and said staple forming and insertion head, means for actuating said staple forming and insertion device to form said component leads over said staple forming blocks as a staple while maintaining said body substantially stress-free, said staple forming and insertion head being adapted for holding the formed staple following forming of said component leads as a staple by virtue of the resilience of the leads, means responsive to com pletion of the actuation of said staple forming and insertion head to form said component as a staple for sep arating said forming blocks, said staple forming and insertion device being arranged and adapted to pass between the separated forming blocks when actuated by said means for actuating, and means for thereafter in serting the bent lead ends through said wafer.

19. A machine for stapling an electrical component to a wafer, said component including a relatively fragile body and a pair of leads secured to said body, wherein said leads are used as stapling elements, comprising a stapling head, means securing said wafer at a position adjacent said stapling head, said stapling head including means for securing and supporting said electrical component by said leads only and at a first element of each of said leads lying adjacent said fragile body, said leads each including a further element extending from the first element, said stapling head including means for bending said further elements only at substantially right angles to said body, and means for inserting the bent further elements partially through said wafer for a distance such that said fragile body remains uncompressed against said wafer.

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